Reusable package for rolled paper products

ABSTRACT

A large count package comprising an overwrap and a plurality of products. The overwrap comprises an opening and wherein a drawstring is positioned around the opening and wherein the drawstring comprises a pull region. The overwrap comprises a volume of from about 1100 in 3  to about 10000 in 3 .

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of provisional U.S. Application No.60/992,730, filed Dec. 6, 2007.

FIELD OF THE INVENTION

The present invention is directed to a package for rolled absorbentpaper products, particularly a package that performs a second functionas a trash bag.

BACKGROUND OF THE INVENTION

Consumers of absorbent paper products, especially or paper towelsanitary tissue products such as paper towels or toilet paper, mayprefer to purchase large count packages (LCPs) instead of single unitsbecause consumers often find it more useful to purchase a large numberof products at once in order to avoid the inconvenience of having tomake repeated trips to the store. Other consumers may prefer to purchasethe large-count packages and keep large quantities of product on-hand inorder to prevent running out of product at inopportune times.

Although large count packages of paper towel products are well known inthe art, a problem that plagues producers and consumers alike is thelarge amount of extraneous packaging material that is used. For example,the overwrap of a large count package is often simply discarded by theconsumers after removal of the products from the package. Unfortunatelyvirtually all products sold in large quantities require a large amountof packaging material (such as overwrap) to secure the productstogether. However, the overwrap is normally discarded once the producthas been used. Additionally, many large count packages are prone tohaving units fall out of the opening once units are removed due to thetearing of the overwrap which a consumer must do in order to access theproduct. Additionally, some users find that large count packages maybecome unwieldy as the number of units inside becomes lower.

Accordingly, there is a need for a package of rolled absorbent paperproducts wherein the package provides additional benefits to the user(i.e., is not simply discarded) while still properly securing theindividual products for transportation and subsequent retail display andsale.

SUMMARY OF THE INVENTION

In one embodiment, the present invention is directed to a large countpackage comprising an overwrap and a plurality of products. The overwrapcomprises an opening and wherein a drawstring is positioned around theopening and wherein the drawstring comprises a pull region. The overwrapcomprises a volume of from about 1100 in³ to about 10000 in³.

In another embodiment, the present invention is directed to a largecount package comprising an overwrap and a plurality of products. Theoverwrap comprises an opening and wherein the overwrap further comprisestwo or more ears extending from the opening. The overwrap comprises avolume of from about 1100 in³ to about 10000 in³.

In yet another embodiment, the present invention is directed to a methodof marketing large count packages of rolled absorbent paper productswherein the method comprises the steps of: providing a plurality ofrolled absorbent paper products in an overwrap wherein the overwrapcomprises an opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of an individual rolledpaper product that may be used in the package of the present invention.

FIG. 2 is a perspective view of an embodiment of a package comprising aplurality of individual rolled paper products of the present invention.

FIG. 3 is a top view of an embodiment of a package that may be used inthe present invention.

FIG. 4 is a perspective view of an embodiment of a package comprising aplurality of individual rolled paper products of the present invention.

FIG. 5A is a perspective view of an embodiment of a package comprising aplurality of individual rolled paper products of the present invention.

FIG. 5B is a top view of an embodiment of a package that may be used inthe present invention.

FIG. 6A is a perspective view of an embodiment of a package comprising aplurality of individual rolled paper products of the present invention.

FIG. 6B is a top view of an embodiment of a package that may be used inthe present invention.

FIG. 7A is a schematic view of an embodiment of the package according tothe present invention being used as a garbage bag.

FIG. 7B is a schematic view of an embodiment of the package according tothe present invention being used as a garbage bag.

DETAILED DESCRIPTION OF THE INVENTION Definitions

As used herein, “product” refers to any article or item which may beprovided in product packaging and/or which may be secured in an overwrapand/or large count package. In a first exemplary embodiment the productmay be a laundry product such as a laundry detergent and/or fabricsoftener. In one embodiment, a product refers to a paper product whichmay be selected from the group consisting of: disposable absorbentarticles, bathroom tissue, napkins, paper towel products, facialtissues, wipes, the like, and combinations thereof. In anotherembodiment, a product refers to a feminine care product which may beselected from the group consisting of: disposable absorbent articles,sanitary napkins, tampons, interlabial products, incontinence articles,liners, the like, and combinations thereof. In another embodiment, aproduct refers to a baby care product which may be selected from thegroup consisting of: disposable absorbent articles, diapers, trainingpants, incontinence articles, wipes, the like, and combinations thereof.

As used herein, “paper product” refers to any formed, fibrous structureproducts, traditionally, but not necessarily, comprising cellulosefibers. Exemplary paper products are described supra.

As defined herein, “product package” refers to any one or more productsenclosed in any one or more product packaging media. In an exemplaryembodiment product packaging media may be selected from the groupconsisting of: overwrap, box, carton, container, the like, andcombinations thereof.

As used herein, “overwrap” refers to any material that may be used tosecure two or more products, paper products, or product packages into aunitary article for transport, and display and/or sale at a retaillocation. In an exemplary embodiment, an overwrap may be provided arounda plurality of products and/or product packages to provide a large countpackage. In one embodiment an overwrap may be plastic. In someembodiments an overwrap may be translucent. In other embodiments anoverwrap may be opaque. In yet other embodiments an overwrap may beprovided with one or more visual elements. In an exemplary embodiment avisual element may be selected from the group consisting of: logos,trademarks, sayings, slogans, pictures, character renditions,photographs, product samples, product representations, holograms,shapes, words, letters, the like, and combinations thereof. In someembodiments an overwrap is a unitary member. In other embodiments, anoverwrap is a bag.

As used herein, “large count package” or “LCP” refers to a container orpackage having a plurality of products and/or product packages securedtherein. In some embodiments, a LCP provides an outerwrap to secure theplurality of products and/or product packages.

As used herein, “roll paper product” refers to any paper product that iswound about an axis. In an embodiment, a roll paper product is providedby winding a paper product around a core.

As used herein, “ply” or “plies”, as used herein, means an individualfibrous structure or sheet of fibrous structure, optionally to bedisposed in a substantially contiguous, face-to-face relationship withother plies, forming a multi-ply fibrous structure. It is alsocontemplated that a single fibrous structure can effectively form two“plies” or multiple “plies”, for example, by being folded on itself. Inone embodiment, the ply has an end use as a tissue-towel paper product.A ply may comprise one or more wet-laid layers, air-laid layers, and/orcombinations thereof. If more than one layer is used, it is notnecessary for each layer to be made from the same fibrous structure.Further, the layers may or may not be homogenous within a layer. Theactual makeup of a fibrous structure product ply is generally determinedby the desired benefits of the final tissue-towel paper product, aswould be known to one of skill in the art. The fibrous structure maycomprise one or more plies of non-woven materials in addition to thewet-laid and/or air-laid plies.

As used herein, “fibrous structure” means an arrangement of fibersproduced in any papermaking machine known in the art to create a ply ofpaper. “Fiber” means an elongate particulate having an apparent lengthgreatly exceeding its apparent width. More specifically, and as usedherein, fiber refers to such fibers suitable for a papermaking process.The present invention contemplates the use of a variety of paper makingfibers, such as, natural fibers, synthetic fibers, as well as any othersuitable fibers, starches, and combinations thereof. Paper making fibersuseful in the present invention include cellulosic fibers commonly knownas wood pulp fibers. Applicable wood pulps include chemical pulps, suchas Kraft, sulfite and sulfate pulps; mechanical pulps includinggroundwood, thermomechanical pulp; chemithermomechanical pulp;chemically modified pulps, and the like. Chemical pulps, areparticularly well suited in tissue towel embodiments since they areknown to those of skill in the art to impart a superior tactical senseof softness to tissue sheets made therefrom. Pulps derived fromdeciduous trees (hardwood) and/or coniferous trees (softwood) can beutilized herein. Such hardwood and softwood fibers can be blended ordeposited in layers to provide a stratified web. Exemplary layeringembodiments and processes of layering are disclosed in U.S. Pat. Nos.3,994,771 and 4,300,981. Additionally, fibers derived from non-wood pulpsuch as cotton linters, bagesse, and the like, can be used.Additionally, fibers derived from recycled paper, which may contain anyor all of the pulp categories listed above, as well as other non-fibrousmaterials such as fillers and adhesives used to manufacture the originalpaper product may be used in the present web. In addition, fibers and/orfilaments made from polymers, specifically hydroxyl polymers, may beused in the present invention. Non-limiting examples of suitablehydroxyl polymers include polyvinyl alcohol, starch, starch derivatives,chitosan, chitosan derivatives, cellulose derivatives, gums, arabinans,galactans, and combinations thereof. Additionally, other syntheticfibers such as rayon, lyocel, polyester, polyethylene, and polypropylenefibers can be used within the scope of the present invention. Further,such fibers may be latex bonded. Other materials are also intended to bewithin the scope of the present invention as long as they do notinterfere or counter act any advantage presented by the instantinvention.

As used herein, “Machine Direction” or “MD” means the direction parallelto the flow of the fibrous structure through the papermaking machineand/or product manufacturing equipment.

As used herein, “Cross Machine Direction” or “CD” means the directionperpendicular to the machine direction in the same plane of the fibrousstructure and/or fibrous structure product comprising the fibrousstructure.

As used herein, “Basis Weight” or “BW” means the weight per unit area ofa sample reported in lbs/3000 ft² or g/m².

In one embodiment, the absorbent paper product substrate may bemanufactured via a wet-laid paper making process. In other embodiments,the absorbent paper product substrate may be manufactured via athrough-air-dried paper making process or foreshortened by creping or bywet microcontraction. In some embodiments, the resultant absorbent paperproduct plies may be differential density fibrous structure plies, wetlaid fibrous structure plies, air laid fibrous structure plies,conventional fibrous structure plies, and combinations thereof. Crepingand/or wet microcontraction are disclosed in U.S. Pat. Nos. 6,048,938,5,942,085, 5,865,950, 4,440,597, 4,191,756, and 6,187,138.

Nonlimiting types of fibrous structures according to the presentinvention include conventionally felt-pressed fibrous structures;pattern densified fibrous structures; and high-bulk, uncompacted fibrousstructures. The fibrous structures may be of a homogenous ormultilayered (two or three or more layers) construction; and thesanitary tissue products made therefrom may be of a single-ply ormulti-ply construction.

In one embodiment, the absorbent paper product is in the form of arolled product. For example, the absorbent paper product is convolutelywound about a core or a void area where a core would be present, if onewas present.

In one example, the absorbent paper product of the present invention isa pattern densified fibrous structure characterized by having arelatively high-bulk region of relatively low fiber density and an arrayof densified regions of relatively high fiber density. The high-bulkfield is characterized as a field of pillow regions. The densified zonesare referred to as knuckle regions. The knuckle regions exhibit greaterdensity than the pillow regions. The densified zones may be discretelyspaced within the high-bulk field or may be interconnected, either fullyor partially, within the high-bulk field. In one embodiment, from about8% to about 65% of the fibrous structure surface comprises densifiedknuckles, the knuckles may exhibit a relative density of at least 125%of the density of the high-bulk field. Processes for making patterndensified fibrous structures are well known in the art as exemplified inU.S. Pat. Nos. 3,301,746, 3,974,025, 4,191,609 and 4,637,859.

The finished fibrous structure may exhibit regions of higher densitycompared to other regions within the finished fibrous structure. Inother words, the finished fibrous structure may comprise a differentialdensity fibrous structure.

The finished fibrous structure may be creped or uncreped and/orforeshortened or not. The finished fibrous structure may be athrough-air-dried fibrous structure, a wet-pressed fibrous structureand/or a conventionally dried fibrous structure.

Rolled Paper Products

FIG. 1 shows an exemplary rolled paper product 10. In one embodiment,the rolled paper product of the present invention is a rolled papertowel product, such as the Bounty® product sold by the Procter & GambleCo (Cincinnati, Ohio). In one embodiment, the rolled paper product has aheight H of from about 4″ to about 13″. In another embodiment, therolled paper product has a height H of from about 4″ to about 11″. Inone embodiment, the rolled paper product has a diameter, D_(roll), offrom about 3″ to about 7″.

Large Count Packages

Products, processes and means for packaging large-count products arewell-known in the art. An exemplary large-count product package isdescribed in U.S. Pat. No. 5,685,428. Plastic garbage and trash bags forbulk waste material may be produced in film form from various polymerssuch as polyethylene. The films used for such bags often possess highstrength characteristics such as puncture toughness and tensilestrength. This may be contrasted to typical outerwrap packaging which isoften relatively thin and has a relatively low strength compared to agarbage bag due to the less strenuous use of outerwrap packaging.Exemplary materials include linear low density polyethylenes. Suitablepackaging means and materials may also be purchased from a vendor suchas the PCMC Co. (Green Bay, Wis.) and the KPL Packaging Co. (Bologna,Italy).

Materials such as those illustrated and described herein as suitable foruse in accordance with the present invention, as well as methods formaking and characterizing the same are described in commonly assignedU.S. Pat. Nos. 5,518,801 and 6,695,476. In one embodiment, a material isa low density polyethylene. In one embodiment the material has athickness of from about 0.001 cm to about 0.005 cm. In anotherembodiment, the material has a thickness of from about 0.002 cm to about0.004 cm. Such a material may be purchased from the Heritage Bag Company(Atlanta, Ga.) or from the Clorox Company (San Francisco, Calif.). Inother embodiments, the bag has a puncture toughness of greater thanabout 7 lbs. In another embodiment, the bag has a puncture toughness offrom about 7 in-lbs to about 20 in-lbs. In one embodiment, the bag hasan MD tensile strength of greater than about 2000 psi. In anotherembodiment, the bag has an MD tensile strength of from about 2000 psi toabout 3500 psi. Tensile strength is measured by ASTM D 882 method A.Puncture toughness is measured by providing a ¾ inch round steel plungerand pushing the plunger through a clamped area of the sample at a rateof about 20 inches per minute using an Instron Tester. The load topuncture of the film specimen is recorded in pounds and the energy topuncture is the integrated area under the load-elongation curve and isrecorded in inch-pounds (in-lbs).

FIG. 2 shows an exemplary embodiment of the present invention overwrap20 having an opening 30 and wherein the overwrap 20 further comprises aplurality of individual rolled paper products. In one embodiment, theoverwrap 20 comprises from about 6 to about 24 individual rolled paperproducts. In another embodiment, the present invention overwrap 20comprises from about 2 to about 36 individual rolled paper products. Inanother embodiment still, the present invention package comprises fromabout 6 to about 12 individual rolled paper products. The overwrap 20may have filled dimensions (i.e., dimensions of an overwrap 20containing full rolls of rolled paper products): In one embodiment, thepackage length, L_(P), is from about 8″ to about 28″. In anotherembodiment, the package height, H_(P), is from about 12″ to about 26″.In another embodiment, the package width, W_(P), is from about 8″ toabout 28″. In other embodiments, the package has a volume of from about1100 in³ to about 10000 in³. In other embodiments still, the package hasa volume of from about 1500 in³ to about 8000 in³. As described supra,in some embodiments, the rolled absorbent paper products are rolledpaper towel products. In other embodiments, the rolled absorbent paperproducts are toilet tissue products. In some embodiments, the volume ofthe package may exceed the volume occupied by the products. In otherembodiments, the volume of the package is approximately equal to thevolume occupied by the products. In an embodiment where the volume ofthe package exceeds the volume of the products occupying the package,the excess packaging may be mechanically, adhesively, or otherwise (asmay be known in the art) contained, such that the products occupying thepackage are secured in place within the package. For example, the excesspackaging may be folded over and then adhesively attached to anotherportion of the package.

The present invention overwrap 20 further comprises a drawstring 40around the opening 30 wherein the drawstring 40 comprises a pull region40 a. In some embodiments, the drawstring 40 may be released to enlargethe area of the opening 30 so that a consumer may be able to open theoverwrap 20 and retrieve individual rolled paper products therefrom.Conversely, in some embodiments, the drawstring may be pulled to reducethe area of the opening 30 after the package has been opened.

Surprisingly, it was found that consumers prefer the benefit of having adrawstring 40 with a pull region 40 a around the overwrap 20 and thepackage having the dimensions described supra because the overwrap 20may then be reused as a garbage bag. Packages and materials for making apackage suitable for use as a garbage bag may be purchased commerciallyfrom Four Star Plastics (Beltsville, Md.) and Primepak Co. (Teaneck,N.J.).

FIG. 3 shows an exemplary embodiment of the overwrap 20 without havingany products placed inside. In the exemplary embodiment, the emptyoverwrap 20 may be flattened such that the package has a flat-packageheight, H_(FP), and a flat-package length, L_(FP). In one embodiment,the flat-package height, H_(FP), is from about 9″ to about 40″. Inanother embodiment, the flat-package length, L_(FP), is from about 7″ toabout 42″. In the exemplary embodiment, the drawstring 40 is providedsuch that the opening 30 may be fully extended to the full flat-packagelength, although in some embodiments the opening does not extend to thefull flat-package length.

In some embodiments, the overwrap 20 that has been filled withindividual rolled paper products may be sealed using any means known inthe art. Exemplary processes and means for sealing packages aredescribed in U.S. Pat. Nos. 5,041,148, 5,015,325, 4,928,455, and3,660,962. FIG. 4 shows an exemplary alternative embodiment of theoverwrap 20 of FIG. 2. In the exemplary embodiment of FIG. 4, theoverwrap 20, containing individual rolled paper products, is sealed atthe opening, and the sealed opening is provided with perforations 45 toprovide ease of opening for the consumer. Without wishing to be limitedby theory, it is thought that retailers prefer to have packages whichare sealed because this provides for easier displaying, storage, andtransporting. In some embodiments, the overwrap 20 may comprise one ormore indicia 60. In one embodiment, the indicia 60 may be selected fromthe group consisting of: logos, trademarks, artwork, drawings, pictures,instructions, directions, information, tips, guidelines, the like, andcombinations thereof. For example, in one embodiment the indicia mayinstruct the consumer how to properly open the package to preserve theuse of the drawstring.

FIG. 5A shows an exemplary embodiment of an alternative embodiment of apresent invention overwrap 20. In the exemplary embodiment, the overwrapis provided around a plurality of products and/or product packages, suchas rolled paper products. The overwrap 20 may be sealed shut or may beleft open. In an embodiment wherein the overwrap is sealed shut, aplurality of perforations 45 may be provided such a consumer may tearthe overwrap along the perforations 45 to access and/or remove productsand/or product packages from the overwrap 20.

FIG. 5B shows an exemplary embodiment of the overwrap 20 of FIG. 5A uponremoval of any product packages. Without wishing to be limited bytheory, it is thought that by providing an overwrap 20 having ears 24which may be used as ties to reclose the overwrap after and may thusprovide consumers with the benefit of being able to reuse the overwrap20 as a trash bag, or the like. It is thought that many consumers willappreciate, and take advantage of, the additional use of the package. Anoverwrap of the present invention may have any shape, size, and numberof ears 24 that is suitable for the intended application.

FIG. 6A shows an exemplary embodiment of an alternative embodiment of apresent invention overwrap 20 having ears 24. In the exemplaryembodiment, the overwrap is provided around a plurality of productsand/or product packages, such as rolled paper products wherein theoverwrap is left open, but the product is secured by providing amechanical mechanism 22. In one embodiment a mechanical mechanism may beselected from the group consisting of: clips, snaps, buttons, strings,ties, Velcro™, the like, and combinations thereof.

FIG. 6B shows an exemplary embodiment of the overwrap 20 of FIG. 5A uponremoval of any product packages.

Method Describing Use of the Package

In some embodiments, the present invention is directed to a method ofmarketing large-count packages of rolled absorbent paper productswherein the method comprises the steps of: providing a plurality ofrolled absorbent paper products in a package, the package comprising anopening and a drawstring around the opening. In another embodiment, themethod further comprises the step of providing an indicium to theconsumer that the package may be reused as a garbage bag. In anotherembodiment, the method further comprises the step of using the packageas a garbage bag.

FIGS. 7A-7B show exemplary embodiments of an overwrap 20 according tothe present invention being used as a garbage bag. Materials for garbagebags are described supra. In the embodiment shown in FIG. 7A, theoverwrap/garbage bag 20 having a drawstring 40 may be used as aso-called liner for a garbage can 29. In the embodiment shown in FIG.7B, the overwrap/garbage bag 20 having two or more ears 24 may be usedas a so-called liner for a garbage can 29.

In another embodiment the overwrap 20 may be reused as a bag or holderfor any purpose. For example, the overwrap 20 may be used as a reusableshopping bag or as a tote bag.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A large count package comprising an overwrap and a plurality ofproducts; wherein the overwrap comprises an opening and wherein adrawstring is positioned around the opening and wherein the drawstringcomprises a pull region; and wherein the overwrap comprises a volume offrom about 1100 in³ to about 10000 in³.
 2. A large count packageaccording to claim 1 wherein the products are paper towel products.
 3. Alarge count package according to claim 1 wherein the individualabsorbent paper products have a height of from about 4″ to about 13″ anda diameter of from about 3″ to about 7″.
 4. A large count packageaccording to claim 1 wherein there are from about 2 to about 36products.
 5. A large count package according to claim 1 wherein theopening is sealed to provide a sealed opening.
 6. A large count packageaccording to claim 5 wherein the sealed opening is perforated.
 7. Alarge count package according to claim 1 wherein the package is usableas a garbage can liner.
 8. A large count package comprising an overwrapand a plurality of products; wherein the overwrap comprises an openingand wherein the overwrap further comprises two or more ears extendingfrom the opening; and wherein the overwrap comprises a volume of fromabout 1100 in³ to about 10000 in³.
 9. A large count package according toclaim 8 wherein the products are paper towel products.
 10. A large countpackage according to claim 8 wherein the individual absorbent paperproducts have a height of from about 4″ to about 13″ and a diameter offrom about 3″ to about 7″.
 11. A large count package according to claim8 wherein there are from about 2 to about 36 products.
 12. A large countpackage according to claim 8 wherein the opening is sealed to provide asealed opening.
 13. A large count package according to claim 12 whereinthe sealed opening is perforated.
 14. A large count package according toclaim 8 wherein the overwrap is usable as a garbage can liner.
 15. Alarge count package according to claim 8 wherein the overwrap has athickness of from about 0.001 cm to about 0.005 cm.
 16. A large countpackage according to claim 15 wherein the overwrap has a thickness offrom about 0.002 cm to about 0.004 cm.
 17. A large count packageaccording to claim 8 wherein the overwrap has a puncture toughness ofgreater than about 7 lbs.
 18. A large count package according to claim17 wherein the overwrap has a puncture toughness of from about 7 in-lbsto about 20 in-lbs.
 19. A large count package according to claim 8wherein the overwrap has an MD tensile strength of greater than about2000 psi.
 20. A large count package according to claim 19 wherein theoverwrap has an MD tensile strength of from about 2000 psi to about 3500psi.
 21. A method of marketing large count packages of rolled absorbentpaper products wherein the method comprises the steps of: providing aplurality of rolled absorbent paper products in an overwrap wherein theoverwrap comprises an opening.
 22. A method according to claim 21further comprising the step of providing instructions to the consumerthat the overwrap may be reused as a garbage bag.